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Structure-Property Relationship of Binder Jetted Fused Silica Preforms to Manufacture Ceramic-Metallic Interpenetrating Phase Composites

Myers, Kyle M
http://rave.ohiolink.edu/etdc/view?acc_num=ysu1464089607

Abstract Details

2016, Doctor of Philosophy in Materials Science and Engineering, Youngstown State University, Department of Civil/Environmental and Chemical Engineering.
Additive manufacturing (AM) is an area of high interest due to its rapid prototyping and high complexity abilities. Powder based AM techniques allow for a wide variety of materials to be studied. Here, the binder jetting of fused silica (SiO2) powders were investigated as precursor materials for subsequent molten metal infiltration and the manufacturing of metal-ceramic interpenetrating phase composites (IPCs). The structure property relationship of cured, sintered, and infiltrated states were correlated to the variables powder size, spread speed, binder saturation, layer thickness, and sintering temperature. The process parameters of the X1-Lab printer were optimized to manufacture the strongest SiO2 ceramic body with the highest density. The printed parts were subsequently infiltrated with molten aluminum to create unique Al/Al2O3 IPCs. The parameters of 48 µm powders, 0.5 mm/sec spread speed, 60% binder saturation, 100 µm layer thickness, and 1500°C sintering temperature resulted in the highest density and compression strength of both the sintered and composite states. It was also found, that the mechanical investigation of the composite materials exhibited a strain-rate dependency that was observed by the split Hopkinson testing. In addition to the aforementioned outcomes, it was found that further densification of the printed parts is required to achieve the full potential of additive manufacturing on synthesizing IPCs for structural applications. A homogenization technique was also carried out via Matlab, and it showed to be a quick and reliable simulation technique to predict the elastic modulus of a two-phase composite system. Finally, alternative processing techniques were explored to create dense printed and infiltrated parts. It was shown that the agglomeration of small particles and the addition of external pressure during the infiltration stage appear to be promising routes for increasing the density of IPCs manufactured via binder jetting.
Pedro Cortes, PhD (Advisor)
Brett Conner, PhD (Committee Member)
Tim Wagner, PhD (Committee Member)
Donald Priour, PhD (Committee Member)
Brian Hetzel (Committee Member)
252 p.
Materials Science
Binder Jetting, Structure-property relationship, Interpenetrating Phase Composites, Additive Manufacturing

Recommended Citations

Citations

  • Myers, K. M. (2016). Structure-Property Relationship of Binder Jetted Fused Silica Preforms to Manufacture Ceramic-Metallic Interpenetrating Phase Composites [Doctoral dissertation, Youngstown State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ysu1464089607

    APA Style (7th edition)

  • Myers, Kyle. Structure-Property Relationship of Binder Jetted Fused Silica Preforms to Manufacture Ceramic-Metallic Interpenetrating Phase Composites. 2016. Youngstown State University, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ysu1464089607.

    MLA Style (8th edition)

  • Myers, Kyle. "Structure-Property Relationship of Binder Jetted Fused Silica Preforms to Manufacture Ceramic-Metallic Interpenetrating Phase Composites." Doctoral dissertation, Youngstown State University, 2016. http://rave.ohiolink.edu/etdc/view?acc_num=ysu1464089607

    Chicago Manual of Style (17th edition)

ysu1464089607
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© 2016, all rights reserved.
This open access ETD is published by Youngstown State University and OhioLINK.